nano-composite cermet coatings hybricomp™...

24112 Rockwell Drive Euclid OH 44118p.216-404-0053 Private & Confidential

Nano-Composite Cermet Coatings

HybriComp™ Boromet™

Corrosion- and wear-resistant thermally sprayed nano-composite coatings that enable longer component life

Private & Confidential 1

Private & Confidential

Advanced Materials and Specialty Metals company:Develops, manufactures and markets advancednanocomposite materials, and innovative fabricatedmetal products for metal protection and repair throughtheir revolutionary “long life” coatings technologies.

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Ceramic-metallic (Cermet), thermal spray coatings to protect metal surfaces. ◦ HybriComP™ W: High toughness, nanocomposite carbide for extreme wear

Binder Coating Improves adhesion and spray

efficiency Provides toughness and resiliency Provides corrosion resistance Prevents compositional changes

Nano Composite Core High hardness and wear resistance Contains nano-dispersed friction

modifiers Provides for fast machining

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Structure


ONLY thermal spray powder line that leads to coatings that are both hard and tough.

Currently available wear-resistant thermal spray coatingshave high hardness but not high toughness. In most cases,the failure mode of the coating is the coating spallation(flaking) and not the coatings wearing-off as it would benormally assumed. With HybriComP™, the coatings do notflake even under high loads and vibration.

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PERFORMANCE3-10X extended life of componentsUnique: Provides both hardness and toughnessEnvironmentally friendly, No toxic waste stream

COSTSignificantly reduces downtimeMassive cost savings due to reduced inventory needsUp to 50% lower life-cycle costLowest life cycle cost solution

TIMEHigher spray efficiency, easier to grind and finish – saves 30% time90% reduction of turnaround time over electro-plating

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HybriComP™ W is a cermet powder fabricated(nanoscale) into a hierarchical structure using apatented process. The nanocomposite corecontains nano and near-nano size WC(Tungsten Carbide) particles in a hard,corrosion resistant alloy binder. This core isencased in a protective metallic cladding thatminimizes the adverse effects of the HVOFspraying process on the hard particles andassists in formation of a hierarchical coatingstructure.

US Patent 7,681,622: HETEROGENEOUS COMPOSITE BODIES WITH ISOLATED LENTICULAR SHAPED CERMET REGIONS

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0

2

4

6

8

10Corrosion

Slidingwear

Abrasivewear

Hardness

Spallation

Coatingcost

HybriComP-W

Conventional WC-Co

EHC


HybriComp™ W104 HybriComp™ W333 HybriComp™ W611


HybriComP W104 Coating

Substrate

Porosity & unmelts less than 1%

Hardness 1250-1600 HV300

Adhesion >70 MPa (10,000 psi)

Residual Stress – Compression

Nano-structured WC-CoCr coating with better wear and ductility than conventional WC-CoCr

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Nominal Chemistry (wt%): WC – 10%Co – 4%Cr



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0.0000

0.0020

0.0040

0.0060

0.0080

0.0100

0.0120

0.0140

0.0160

EHC WC-CoCr WC-CoCr

Hard Chrome Conventional HybriComP-W 104

Wei

ght l

oss

[cc]

ASTM G-65 Sand Abrasion Results



10

0

0.00001

0.00002

0.00003

0.00004

0.00005

0.00006

0.00007

0.00008

EHC WC-CoCr WC-CoCr

Hard Chrome Conventional HybriComP-W104

Wei

ght l

oss

[cc]

ASTM F1978 Dry Abrasion Test Results


EHC, 165 hrs

ASTM B-117 Corrosion Results

Superior corrosion resistance compared with EHC

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After 6 months of side-by-side utilization, HybriComP™-W104 coated roller screens looked as good as new

The rolls protected with the steel company’s existing coatings dimensional loss of 6 mm to 15 mm and required replacement.

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INSERT W333 MICROSTRUCTURE

PIC

100 µm

HybriComPTM W333 Coating

Substrate

Premium high toughness nano-engineered tungsten carbide-nickel-chrome (WC-NiCr) material, with 5-7x the ductility and toughness of conventional carbides

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Nominal Chemistry (wt%): WC-13%Ni – 3%Cr – 3%Co



15

0

0.005

0.01

0.015

0.02

0.025

Cr WC-basiert WC-17Co Cr3C2-NiCr

EHC HybriComP

W333Diamalloy

2005Diamalloy

3004

Volu

men

verlu

st[c

c] M

etho

deB

ASTM G-65 Sand Abrasion Results


EHC, 165 hrs

ASTM B-117 Corrosion Results

Superior corrosion resistance compared with EHC

HybriComP-W333, 1000 hrs

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0.004” Coating Thickness 0.010” Coating Thickness

Mandrel

Coating

Substrate

Static support

180° Tensile Bend Testing


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Coated Plungers, Mandrels and Pump Components

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Nano-structured WC-17Co coating with better wear and ductility than conventional WC-17Co

100 µm

Substrate

HybriComP-W611 coating

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Nominal Chemistry (wt%): WC – 17%Co



200 µm

Coating

Substrate

Embedding resin

5 µm

WC-particles

Nano-X powder structure is preserved in the coating Un-melt WC particles are well embedded in homogenous binder Primarily submicron structure with many nano-scaled phases

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Reciprocating Rod/Bushing Wear Test

288 lbf normal load, 1” stroke, 3 Hz

Radco FR 282 hyd fluid

Weight Pan

Load Cell

ServohydraulicActuator

Drive Rod

UDRI Test Cell

Sliding Wear Results

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0

0.1

0.2

0.3

0.4

0.5

0.6

0 50000 100000 150000 200000 250000

Cum

ulat

ive

Wei

ght l

ost (

mg)

Number of Cycles

HybriComP-W

WC

EHC



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0

0.005

0.01

0.015

0.02

0.025

Cr WC-based WC-17Co Cr3C2-NiCr

EHC HybriComP-W Diamalloy 2005 Diamalloy 3004

Volu

me

Loss

[cc]

M

etho

d B

Testing Completed at Stork LaboratoriesASTM G-65 Sand Abrasion Results


“Big Bar” Test Specimen Sample length 12.10”◦ OD 2.25”◦ 20 cycles


Spallation Test Setup (UDRI)

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Coating Bar Diameter (inch)

Nominal Coating

Thickness (inch)

Failure Stress (ksi)

Failed on Cycle no. Comments

HybriComP-W 2.2705 0.01 No Failure N/A Tested at 240 ksi twice w/o failure

“ 2.2690 0.01 No Failure N/A Tested at 240 ksi twice w/o failure

“ 2.2695 0.01 230 15 Failed after the second run at 230 ksi

Conventional WC-Co 2.2700 0.01 200 9

“ 2.2705 0.01 200 2

EHC 2.2710 0.01 No Failure N/A Tested at 240 ksi

“ 2.2710 0.01 No Failure N/A Tested at 240 ksi

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24112 Rockwell Drive Euclid OH 44118p.216-404-0053 Private & Confidential

BOROMET™Feedstock ceramic solution to reduce molten Zinc attack on components and tools

Touch rolls

Corrector roll

Detector roll

Sinker roll

Molten Zinc

Steel sheet

- Since Zn at the relevant temperatures reacts with iron from the steel sheet as well as with the surface of the rolls by causing their dissolution, dross is built up.

- Dross attaching causes at high processing temperatures a further corrosion of rolls by Zn-diffusion through the dross layer and deteriorates the rolls functionality.

State-of-the-art

Dross build-up on the outer edge of the roll

State-of-the-art

West Virginia University, 2005

Zinc corrosion attack on WC-Co coatings

Zinc Reactivity

Matthews et al. JTST 2010

Alloy System Ag-Zn Al-Zn As-Zn Au-Zn B-Zn Ba-Zn Bi-Zn Cd-Zn Ce-Zn

Co-Zn Cr-Zn Cu-Zn Fe-Zn

Amount of Zinc dissolved Ag 4 % + 96 % Zn liquid

Al 32 % + 68 % Zn liquid As 0 % - 100 % Zn liquid Au 10 % + 90 % Zn liquid

No phase diagram Ba 1.2 % + 98.8 % Zn liquid

Bi 5 % + 95 % Zn liquid Complete dissolution

Ce 1 % + 99 % Zn

Co <0.1 % + Zn Cr 0.8 % + Zn Cu 4 % + 96 % Fe ∼ 0.1 + Zn

º Coatings must be dense (almost zero porosity), since molten bath can diffuse through open porosity and attack the substrate

º Must feature an adjusted CTE to the substrate to eliminate cracking and spallation at high temperatures.

State-of-the-art / Coatings

3

138

274

209

358

<600

0

100

200

300

400

500

600

700

AlSi316L Al2O3 YSZ WC-Co WC-Co lowcarbon

MoB/CoCr

Tim

e to

dis

solv

e [h

ours

]

Commercially available MoB/CoCr coatings after 1007 hours testing in molten zinc bath

0.02 mm

0.05 mm0.24 mm Substrate

Coating

Substrate

Coating

Zinc

State-of-the-art / Coatings

Sample

Resistance wire

Molten Zinc

Resistance furnace

90 mm

10 mm

Testing – set-up

Test Conditions: - Bath temperature: 800F (427°C) for Zn- 48 hours testing interval(the specimens were removed from the molten test, inspected, macro analyzed and immersed again if no damage)

As-sprayedRoughness: 2.36 µm

As tested on Zinc pot

After Zn removing

Results / After 3000 hrs. testing

Coated part

Uncoated part

Zinc

Body over zinc (vapor

zone)

Tip in zinc (melted zone)

Body over zinc (vapor zone)

After 3000hrs testing

Tip in zinc (melting zone)After 3000 hrs testing

As sprayed

Morphology

300

400

500

600

700

800

900

1000

1100

Vapor zone Melting zone

As sprayed After Zinc testing After Zinc testing

Har

dnes

s [H

V0.3

]Hardness before and after 3000 hrs. testing in molten zinc

Vapor zone

Melting zone

Time to Damage

Melting points: Al45%Zn – 620°C; 55%Al-Zn-1.5%Si – 580-600°C; Zn – 420°C

3138

274 209358

600

7120

213

>3000 (tested at Powdermet)

>3000 (tested at Powdermet)

336 (testedat Powdermet

1007 (testedat Powdermet

0

500

1000

1500

2000

2500

3000

3500

AlSi316L Al2O3 YSZ WC-Co WC-Co lowcarbon

MoB/CoCr Al2O3 WC-Co WC-CoCr Boromet Boromet WC-Co MoB/CoCr(Com.

availablepowder)

Molten Al-45wt%Zn Molten 55wt%Al-Zn-1.5wt% Si Molten Al-98wt%Zn

Molten Zn

Tim

e to

dam

age

[hou

r]

Testing in simulated Environmental Conditions (CalSteel)

After stripping

Results after 4 weeks testing

º No corrosion attack

º No thermal shock damage

º No dross built-up

º No thickness / morphology change

º Only surface color change from metallic to reddish (combination ternary oxides)

Before stripping

Better than tested Conventional CoatingsOver 3000 hrs testing without corrosion or thermal shock damage

3x life of commercially available WC-Co coatings

Improve Cost EffectivenessReduced frequency of stoppages and replacement

Reduced Zinc loss due to change of roller assembly

Fewer cycles of re-machining of sink roll

Reduced energy and time consumption since the sink rolls have to be re-heated to the temperature of the bath

In-field test results ongoing (Galvalume and other Zinc variants)Large Producer India (Zinc-0.8%Al)

Sink and stabilizer rolls have lasted 65,000+ tons (without stoppages)

Competing materials last 45,000 tons

Evolution of the pins under thermal fatigue in molten galvalume for more than 2000 hrs.

2/2/2020 Private & Confidential

97 hrs.

97 hrs.

452 hrs.

952 hrs.

1519 hrs.

2044 hrs.

Pins thermal sprayed and tested under galvalume on microgroove and spiral groves


567 hrs.

2117 hrs.

As Machined As HVOF TS As Sealed


1. 316L Roll 2. Grit Blasted

3. HVOF coated 4. Sealed &Cured


Example of Stab rolls under Galvalume

• production run 12.46 Days

• Same rolls after acid dipped, Ready for sealant application and curing.

2/2/2020


•1 campaign compared to their longest life

Increasing Campaign Life

•Coating will increase the roll life

Decrease Roll Grind Frequency

•Roll texture eliminated hydroplaning/scratching condition•Faster turnaround time = less rolls in circulation

AdditionalBenefits

24112 Rockwell Drive Euclid OH 44118p.216-404-0053

Titanium Nitride base CermetsHYBRICOMP™ T45

Nano-structured TiN coating for Industrial Hard Chrome Replacement


Uniform Microstructure

Porosity < 1%

Unmelts < 1%

Hardness = 600-850 HV0.3

Density = 6.5-6.6 g/cc

Low Friction Coefficient <0.1

HYBRICOMP T45 Coating


0.012

0.013

0.014

0.015

0.016

0.017

0.018

0.019

0.02

Cr TiN-based

EHC HybriComP-T

Volu

me

Loss

[cc]

M

etho

d B


0

5

10

15

20

25

PVD HVOF HVOF HVOF

CrN Cr3C2-NiCr WC-17Co HybriComP-T

Blo

ck V

olum

e Lo

ss [m

m3

-3]


HYBRICOMP-T shows 80-fold reduction in system wear rate

Friction coefficient of 0.032, lowest tested

0

0.02

0.04

0.06

0.08

0.1

0.12

HVOF Plasma HVOF HVOF

Ni-Mo Ni-Cr2O3 Cr3C2-NiCr PComP-T

Stat

ic C

oeffi

cian

t of F

rictio

n

0

2

4

6

8

10


Ni-Mo Ni-Cr2O3 PComP-T Cr3C2-NiCr

Volu

me

Loss

[mm

3 ]

Coating Wear

Pin Wear

Total

0.00E+00

1.00E-07

2.00E-07

3.00E-07

4.00E-07

5.00E-07

6.00E-07


Ni-Mo Ni-Cr2O3 PComP-T Cr3C2-NiCr

Wea

r Coe

ffici

ent

[mm

3 /Nm

]

T45T45

T45


Powdermet Test Grinding wheels typically used for EHC Speeds and feeds typical for EHC

grinding Grinding was plunge and (short)

traverse

UDRI Test Al2O3, SiC or Diamond grinding

wheels

HYBRICOMP-T45 Coated Plungers and Finished by Using SiCGrinding Wheels

Best surface w/ Type J SiC 100 wheel• Surface finish, Ra 4.1 µin (plunge)• Surface finish, Ra 4.3 µin (traverse)


Superior Corrosion Resistance

EHC, 165 hrs

HYBRICOMP T45, 1000 hrs



Materials. Technology. Performance.

Highest Value Solutions – 3-10X better corrosion and wear performance compared to current state-of art at the lowest life-cycle cost

Proven technology platform with meaningful sales in some of the most challenging environments

On-track to qualify with several major OEM’s and end users across the globe

Established Partnerships in Canada, Mexico, India, Taiwan, China and Middle East

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nano-composite cermet coatings hybricomp™...

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